Segmented dies for use with ultrasonics

ABSTRACT

A forming die that includes a body, wherein the body of the forming die includes at least one opening created therein; at least one die segment, wherein the at least one die segment is adapted to be inserted into the at least one opening in the body of the forming die, and wherein the at least one die segment is further adapted to receive ultrasonic vibrations; and at least one geometric feature formed within the at least one die segment, wherein the at least one geometric feature affects the ultrasonic vibrations in a predetermined manner.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a continuation-in-part of U.S. patentapplication Ser. No. 14/802,386 filed on Jul. 17, 2015 and entitled“Segmented Dies for Use with Ultrasonics”, which claimed the benefit ofU.S. Provisional Patent Application Ser. No. 62/025,826 filed on Jul.17, 2014 and entitled “Ultrasonic Excitation of Segmented Dies” thedisclosures of which are hereby incorporated by reference herein intheir entirety and made part of the present U.S. utility patentapplication for all purposes.

BACKGROUND OF THE INVENTION

The described invention relates in general to manufacturing systems andmethods and more specifically to a system and method for applyingultrasonic excitation to segmented dies used in manufacturing processessuch as those used in the automotive industry.

The potential of using ultrasonic vibrations to reduce friction duringsheet metal forming processes, e.g. in deep drawing, has been recognizedand investigated over the years, with favorable results having beenreported, both in forming processes, and in the fundamental mechanics offriction reduction. One sheet metal forming area where ultrasonicfriction reduction would presumably have a major benefit is in theforming/stamping of auto body parts. In this field, new challenges arecontinually emerging as efforts are made to form higher strength steeland aluminum alloys having complex shapes. However, in forming andstamping of auto body parts and the like, large steel dies, blankholders and punches are used, not uncommonly having weights in excess ofseveral thousand kilograms and lateral dimensions on orders of metersand of significant thicknesses. Unfortunately, achieving ultrasonicexcitation of such large masses is beyond the current capabilities ofhigh power ultrasonic systems and would seemingly rule out this field ofapplication. Furthermore, current industry methods for frictionalleviation typically involve the application of coatings to a diesurface, which has the disadvantages of (i) requiring renewal as itwears away with repeated stampings; (ii) leaving residues on the stampedsheet metal surfaces which must be later removed; and (iii) thesubsequent disposal of those residues.

However, three primary factors suggest that there are significantapplications for high power ultrasonics (HPU) in the forming of autobody parts and the like. First, in the stamping of auto parts, it hasbeen observed that only certain critical areas of a die are unusuallychallenging to the forming operation. Thus, while a die may indeed be oflarge size and mass, only a comparatively small region might have a formor shape factor that may compromise die performance. Accordingly, theamount of die volume/mass associated with a problem region could bewithin a range that could be feasibly vibrated by ultrasonic vibrations,provided that region could be acoustically isolated from the remainingdie mass. Secondly, it is current practice to segment portions of a diefor various purposes, but most notably to permit repair or replacementof high wear regions. Although it would seem that the boundaries of thesegmented regions would be susceptible to causing marking of the stampedparts, the stamping process is actually fairly tolerant of die surfacedetails insofar as part markings. Thirdly, through prior work onultrasonic friction reduction, processes have been developed foracoustically isolating and securing ultrasonically excited blocks thatare believed able to find application to the present issue of bothultrasonically vibrating a die segment and securing it within an overalldie structure. Thus, there is an ongoing need for a system for applyingultrasonic excitation to segmented dies.

SUMMARY OF THE INVENTION

The following provides a summary of certain exemplary embodiments of thepresent invention. This summary is not an extensive overview and is notintended to identify key or critical aspects or elements of the presentinvention or to delineate its scope.

In accordance with one aspect of the present invention, a first formingdie is provided. This forming die includes a body, wherein the body ofthe forming die includes at least one opening created therein; at leastone die segment, wherein the at least one die segment is adapted to beinserted into the at least one opening in the body of the forming die,and wherein the at least one die segment is further adapted to receiveultrasonic vibrations; and at least one geometric feature formed withinthe at least one die segment, wherein the at least one geometric featureaffects the ultrasonic vibrations in a predetermined manner.

In accordance with another aspect of the present invention, a secondforming die is provided. This forming die includes a body, wherein thebody of the forming die includes at least one opening created therein;at least one die segment, wherein the at least one die segment isadapted to be inserted into the at least one opening in the body of theforming die, and wherein the at least one die segment is further adaptedto receive ultrasonic vibrations; at least one source of ultrasonicvibrations in communication with the at least one die segment fordirecting ultrasonic vibrations into the die segment, wherein the atleast one source of ultrasonic vibrations is either embedded within theat least one die segment or external to the at least one die segment;and at least one geometric feature formed within the at least one diesegment, wherein the at least one geometric feature affects theultrasonic vibrations in a predetermined manner.

In yet another aspect of this invention, a third forming die isprovided. This forming die includes a body, wherein the body of theforming die includes at least one opening created therein; at least onedie segment, wherein the at least one die segment is adapted to beinserted into the at least one opening in the body of the forming die,and wherein the at least one die segment is further adapted to receiveultrasonic vibrations; and at least one geometric feature formed withinthe at least one die segment, wherein the at least one geometric featureaffects the ultrasonic vibrations in a predetermined manner, and whereinthe at least one geometric feature includes a cylindrical bore that isoriented transversely, side-to-side, within the at least one diesegment; a cylindrical bore that is oriented vertically within the atleast one die segment; a square cutout that is oriented verticallywithin the at least one die segment; a rectangular cutout that isoriented transversely, side-to-side, within the at least one die segmentat a predetermined angle; or combinations thereof.

Additional features and aspects of the present invention will becomeapparent to those of ordinary skill in the art upon reading andunderstanding the following detailed description of the exemplaryembodiments. As will be appreciated by the skilled artisan, furtherembodiments of the invention are possible without departing from thescope and spirit of the invention. Accordingly, the drawings andassociated descriptions are to be regarded as illustrative and notrestrictive in nature.

DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated into and form a partof the specification, schematically illustrate one or more exemplaryembodiments of the invention and, together with the general descriptiongiven above and detailed description given below, serve to explain theprinciples of the invention, and wherein:

FIG. 1 is a perspective view of a forming die in accordance with anexemplary embodiment of the present invention showing the ultrasonicallyexcited die segment removed from the body of the forming die;

FIG. 2 is a perspective view of the forming die of FIG. 1, wherein theultrasonically-excited die segment has been fully mounted and securedwithin the body of the forming die;

FIG. 3 is a perspective view of a forming die in accordance with anexemplary embodiment of the present invention showing theultrasonically-excited die segment removed from the body of the formingdie and also showing the adapting fixture mounted within the body of theforming die;

FIG. 4 illustrates the general three dimensional vibrations that occurin the ultrasonically-excited die segment of this invention as well asthe length, width and depth dimensions;

FIG. 5 illustrates the general directions of ultrasonic vibrationsacross the surface of the ultrasonically-excited die segment that arepreferred for achieving maximum friction reduction effects;

FIG. 6 is a perspective view of an embodiment of the present invention,wherein ultrasonically-excited die segment includes a plurality of slotsformed therein; and

FIG. 7 is a perspective view of an embodiment of the present invention,wherein the ultrasonically-excited die segment includes a plurality ofcylindrical columns or holes formed therein.

FIG. 8 is a perspective view of a forming die in accordance with anotherexemplary embodiment of the present invention showing the placement oftwo ultrasonically-excited die segments within the body of the formingdie;

FIG. 9 is a perspective view of one of the ultrasonically-excited diesegments of FIG. 8 shown without any internal features that affect thevibration amplitude of the segment;

FIG. 10 is a perspective view of one of the ultrasonically-excited diesegments of FIG. 8, wherein the ultrasonically-excited die segmentincludes transverse cylindrical bores having different diameters formedtherein;

FIG. 11 is a perspective view of one of the ultrasonically-excited diesegments of FIG. 8, wherein the ultrasonically-excited die segmentincludes a plurality of vertical bores formed therein;

FIG. 12 is a perspective view of one of the ultrasonically-excited diesegments of FIG. 8, wherein the ultrasonically-excited die segmentincludes at least one vertical square cutout formed therein;

FIG. 13 is a perspective view of one of the ultrasonically-excited diesegments of FIG. 8, wherein the ultrasonically-excited die segmentincludes a transverse cylindrical bore formed therein; and

FIG. 14 is a perspective view of an embodiment of the present invention,wherein at least one of the ultrasonically-excited die segments of FIG.8 includes a plurality of transverse, angled, rectangular cutouts formedtherein.

DESCRIPTION OF THE INVENTION

Exemplary embodiments of the present invention are now described withreference to the Figures. Although the following detailed descriptioncontains many specifics for purposes of illustration, a person ofordinary skill in the art will appreciate that many variations andalterations to the following details are within the scope of theinvention. Accordingly, the following embodiments of the invention areset forth without any loss of generality to, and without imposinglimitations upon, the claimed invention.

The purpose of the present invention is to apply ultrasonic vibrationsto one or more regions of a large stamping die in order to reducefriction between the sheet metal being formed and the surface of thedie, thereby improving the formability of the metal at critical shapelocations, as well as reducing galling, tearing and cracking of thesheet metal. This desired effect is accomplished by acousticallyisolating a segment (or segments) of the die and embedding within thedie, an ultrasonic vibration source (i.e., an ultrasonic transducer)that creates resonant vibrations of the die, of varying magnitudes, atits several surfaces thereby creating an ultrasonic friction reductioneffect having various benefits. Thus, the present invention typicallyincludes the steps of: (i) identifying a critical region (or regions) ofa die where friction reduction would have greatest effect (or effects);(ii) acoustically isolating a segment (or segments) of the die, from thecritical region (or regions) into a manageable mass (or masses) that iscapable of being ultrasonically excited; and (iii) incorporating withinthat mass a source of ultrasonic excitation, i.e., an ultrasonictransducer system. The ultrasonic excitation of the die segment by aninternal source versus transmitting vibrations from an external sourceto the die segment along with the specific means of its acousticisolation, are among the novel features of the invention.

With reference now to the Figures, a first exemplary embodiment of anacoustically isolated ultrasonic die is shown in FIGS. 1-2. In FIG. 1,die assembly 10 includes die segment 12, which is adapted to be excitedwith ultrasonic/acoustic vibrations; a portion of a large stamping die14; and low friction pads 26 (or similar devices) that are operative toprovide acoustic isolation die segment 12 when ultrasonic vibrations areapplied thereto. In FIG. 1, die segment 12 is shown separated from largestamping die 14, wherein in FIG. 2, die segment 12 is seated within aportion of large stamping die 14. As shown in FIG. 1, acoustic isolationof die segment 12 involves an adaption of portion of large stamping die14 to specifically accommodate die segment 12. In addition to theopening created in portion of large stamping die 14 for die segment 12,low friction isolation pads 16 may be affixed to portion of largestamping die 14, and/or set screws or other threaded components may beutilized to secure die segment 12 within portion of large stamping die14. Various means for ultrasonically exciting die segment 12, such anexternal ultrasonic transmission line or an embedded internal excitationmechanism (i.e., transducer), may be used (not shown in the Figures).For use in the present invention, the piezoceramics in an ultrasonictransducer are typically pre-compressed to prevent tensile fracture.

With regard to holding ultrasonic die segment 12 within a portion oflarge stamping die 14, it is important to acoustically isolate theultrasonic die segment from the surrounding die structure, while at thesame time securing it in a fixed location so that it seamlessly mergesinto the overall die. Two approaches, which may be used alone or incombination with one another include: (i) low friction pads 16, whereinthe pads include a Frelon coating or are made from a metallic bearingmaterial such as bronze or cast iron; and (ii) a setscrew engagement.The surrounding die structure should be capable of some disassembly inorder to insert ultrasonic die segment 12 as well as to provide accessfor the electrical (and possibly air) connections to the die segmentinsert. Low friction pads 26 may be screw-in inserts, and while theseinserts may be sufficient to secure die segment 12, a set screw methodmay also be modified for this purpose.

One important aspect of the present invention generally, is the minimalmodification a large die for accommodating a die segment that will beexcited with ultrasonic energy. While adjustment or modification of alarge die for accommodating the general block dimensions of die segment12 is possible (because current die practice allows for die segments) itmay not always be practical to modify a large die to accommodate thevarious features of a particular die segment. Accordingly, in someembodiments, die segment adapting fixture 18 is included for moreeffectively placing die segment 12 into at least one portion of largestamping die 14. FIG. 3 provides a generalized image of this embodiment.Die segment adapting fixture includes features that hold, position, andacoustically isolate die segment 12 from the remainder of the largestamping die. Die segment adapting fixture 18 is not typicallyacoustically active and is not intended to vibrate at ultrasonicfrequencies. Die segment adapting fixture 18 is configured to be easilyattached to large stamping die 14, usually in a recess, opening, oraperture created for receiving the fixture. Die segment adapting fixture18 may be attached to a large die in the same manner as die segment 12.

The present invention has been described herein in reference to formingdies. A typical stamping/forming operation consists of the forming die,a blank holder and a punch, each of which may have large mass anddimensions (as noted earlier for a die). This invention, i.e., anultrasonically activated, embedded die insert, may be applied to blankholders or punches, as well. By means of this invention it is possibleto create ultrasonic vibrations in a critical segment or segments of alarge die that would otherwise be impossible to ultrasonically excite toany significant vibration level, and in so doing, to reduce frictionforces between sheet metal being formed and the forming die at one ormore critical forming locations on the die.

With regard to the size and dimensions of die segment 12, FIG. 4illustrates the general three dimensional vibrations that occur in suchdies as well as the length, width and depth dimensions (L, W and D).Also shown in FIG. 4 are the two ultrasonically active die faces thatcontact deforming metal in a manufacturing process, with the other facesbeing embedded within the large stamping die 14 or within die segmentadapting fixture 18. Determining the practical size of an ultrasonic diesegment 12 that provides the desired ultrasonic vibrations for frictionalleviation in the forming process is also an aspect of this invention.For ultrasonic sheet metal forming, the ultrasonic vibrations on thesurface of die segment 12 will preferably be in the general directionsshown in FIG. 5, for achieving maximum friction reduction effects. Thus,the surface of the die typically includes vibration components that areboth perpendicular to the surface and parallel to the surface in thegeneral direction of the deforming metal sliding along its surface. Thisresult is achieved by restricting the length L of the die segment toapproximately an acoustic half wavelength (about 5 inches for a steeldie at 20 kHz) in its longitudinal dimension and the width and depth ofthe die segment to approximately one quarter of an acoustic wavelength(about 2.5 inches for a steel die at 20 kHz) or less in its lateraldimension, while its vibrational motion is restricted to purelylongitudinal at its ends and purely lateral in its middle region. Ifdimensions significantly exceed these limits, additional complexvibration modes may enter, and the surface of the die can take on acomplex vibration pattern that may negatively affect friction reduction.However, large stamping dies may have regions requiring ultrasonicfriction reduction that significantly exceed these acoustically imposedlimits, especially those in the width direction.

Accordingly, one aspect of the present invention includes creatingcontrolled vibrations on a die surface by embedding, within the body ofthe die and/or in non-contacting die surfaces, various geometricfeatures that modify surface vibrations and facilitate the frictionreduction performance of the die. As will be appreciated by one ofordinary skill in the art, it is known to incorporate slot features inultrasonic plastic welding horns for achieving uniform vibration acrossa welding surface, which is essential for creating a uniform weld. Whileslotting of this nature demonstrates that geometric features can be usedto affect surface vibrations occurring on certain ultrasonic tooling,such slots are not necessarily compatible with ultrasonic metal formingdies because a smooth forming surface against the formed metal isrequired. To overcome this limitation, certain embodiments of thisinvention include various geometric features that are embedded withinthe body of die segment 12 and/or at the die surfaces that are not incontact with formed metal. These geometric features are effective forcreating a desired or predicable ultrasonic vibration pattern at theforming surfaces of the die.

In the embodiment shown in FIG. 6, slots placed internally within diesegment 12 permit increasing the die width W well beyond the acousticquarter-wave limit that would normally apply. As shown in FIG. 6,internal rectangular or square slots 20 are machined into die segment 12from the back of bottom and are not surface breaking at the die formingsurfaces. FIG. 7 depicts an embodiment that includes internalcylindrical holes 22 rather than slots 20. The precise geometric shapeand positioning of such internal features will be subject to the generalsize and shape of the overall die segment, which will be dictated by thespecific forming process being used. The use of computer analysis (e.g.finite element analysis (FEA)) permits specific details of the internalfeatures to be determined by analytical means, which then guides finaldie design and fabrication. Using this approach, it is possible toincrease the dimensions of ultrasonic segmented dies to the sizes neededfor most if not all practical forming processes. Using this method ofincreasing the overall width of die segment 12, multiples of theacoustic quarter-wavelength can be achieved such as, for example, up toan acoustic half-wavelength or acoustic full wavelength (e.g., 2.5inches for a steel die at 20 kHz up to 10 inches in width).

As described above, an important feature of the present invention isthat certain predetermined segments of a large die used in ultrasonicsheet metal forming, used for the automotive, aerospace, and consumerproducts industries, for example, can be acoustically isolated from thebalance of a massive die structure, thereby permitting ultrasonicvibrations to be concentrated in small, critical forming regions of thedie, such as corners and sidewalls (see FIG. 8). This feature of thepresent invention allows maximum application and effect of theultrasonic vibrations used in the forming process, without vibrationalenergy being transmitted (and ultimately lost) to adjacent regions ofthe die mass. The segmented die shown in FIG. 8 includes certainperformance enhancements, including force reductions and reduced springback. However, the performance of the segmented die may be furtherimproved by: (i) increasing the overall size and total mass of the die(as described above), thereby permitting its use in large die systems(see FIGS. 6-7); and (ii) modifying the distribution of vibrationamplitude of the die surface to improve friction reductioncharacteristics by altering the die surface at critical locations. Thedimensions of die segments such as those shown in FIG. 8 are typicallyabout 5 inches in length, 2 inches in width and 2 inches in height. Asdiscussed above, these are the approximate acoustic limiting dimensionsof a solid die vibrating in its first longitudinal mode. Furthermore,the axial vibration is at a maximum at the ends of the die segment,while the transverse vibrations are a maximum in the middle of the diesegment. While these vibrations have proven beneficial, greater benefitsare realized if the overall size of the die segment is increased and thevibration pattern is altered/modified.

With reference to FIGS. 9-14, certain embodiments of this inventionprovide structural features that further enhance the performance of thesegmented dies described herein beyond die force reduction and reductionin springback. These embodiments provide various features for modifyingand amplifying the vibration amplitude and vibration distributioncharacteristics of the ultrasonic segmented die without altering theexposed forming surface characteristics of the die, which typicallyinclude a smooth, uniform surface with specific shape features, e.g.curvature of the leading edge of the die. FIG. 8 provides a perspectiveview of a forming die in accordance with an exemplary embodiment of thepresent invention showing the placement of two ultrasonically-exciteddie segments within the body of the forming die. In FIG. 8, die assembly30 includes side wall ultrasonic die segment 32, to which firstsonotrode 34 is connected; corner ultrasonic die segment 36, to whichsecond sonotrode 38 is connected; and forming die body 40. FIG. 9provides an illustration of an ultrasonically-excited die segment thatdoes not include any internal structural features for shaping vibrationamplitude, wherein FIGS. 10-14 provide multiple examples of suchinternal modifications. Modifications other than those shown in theFigures are also contemplated by and included as aspects of thisinvention.

FIG. 9 provides a perspective view of ultrasonically-excited die segment100, which includes sonotrode tip 102, which extends into die segment100 and is connected thereto or in physical contact therewith forproviding ultrasonic energy to the die segment. FIG. 10 provides aperspective view of ultrasonically-excited die segment 200, whichincludes sonotrode tip 202, which extends into die segment 200 and isconnected thereto or in physical contact therewith for providingultrasonic energy to the die segment. Die segment 200 also includes aplurality of first transverse cylindrical bores 204 formed therein; anda plurality of second transverse cylindrical bores 206 formed therein,each of which have a different diameter than the diameter of each firsttransverse cylindrical bore 204. FIG. 11 provides a perspective view ofultrasonically-excited die segment 300, which includes sonotrode tip302, which extends into die segment 300 and is connected thereto or inphysical contact therewith for providing ultrasonic energy to the diesegment. Die segment 300 also includes a plurality of vertical bores 304formed therein. FIG. 12 provides a perspective view ofultrasonically-excited die segment 400, which includes sonotrode tip402, which extends into die segment 400 and is connected thereto or inphysical contact therewith for providing ultrasonic energy to the diesegment. Die segment 400 also includes a vertical square or rectangularcutout 404 formed therein. FIG. 13 provides a perspective view ofultrasonically-excited die segment 500, which includes sonotrode tip502, which extends into die segment 500 and is connected thereto or inphysical contact therewith for providing ultrasonic energy to the diesegment. Die segment 500 also includes a transverse cylindrical bore 504formed therein. FIG. 14 provides a perspective view ofultrasonically-excited die segment 600, which includes sonotrode tip602, which extends into die segment 600 and is connected thereto or inphysical contact therewith for providing ultrasonic energy to the diesegment. Die segment 600 also includes a plurality of transverse angledrectangular cutouts 604 formed therein. As previously indicated,numerous other geometric features are possible and all such features areconsidered to be within the scope of this invention.

While the present invention has been illustrated by the description ofexemplary embodiments thereof, and while the embodiments have beendescribed in certain detail, it is not the intention of the Applicant torestrict or in any way limit the scope of the appended claims to suchdetail. Additional advantages and modifications will readily appear tothose skilled in the art. Therefore, the invention in its broaderaspects is not limited to any of the specific details, representativedevices and methods, and/or illustrative examples shown and described.Accordingly, departures may be made from such details without departingfrom the spirit or scope of the applicant's general inventive concept.

1. A forming die, comprising: (a) a body, wherein the body of theforming die comprises: a cavity circumscribed by the body and at leastone opening in the body; (b) at least one die segment, wherein the atleast one die segment is adapted to be inserted into the at least oneopening in the body of the forming die and be adjacent to the cavity,and wherein the at least one die segment is further adapted to receiveultrasonic vibrations; and (c) optionally, at least one geometricfeature formed within the at least one die segment, wherein the at leastone geometric feature affects the ultrasonic vibrations in apredetermined manner.
 2. The forming die of claim 1, further comprisingat least one source of ultrasonic vibrations in communication with thedie segment for directing ultrasonic vibrations into the die segment. 3.The forming die of claim 2, wherein the at least one source ofultrasonic vibrations is either embedded within the die segment orexternal to the die segment.
 4. The forming die of claim 1, furthercomprising at least one vibration-isolating device positioned betweeneach die segment and the body of the forming die, wherein the at leastone vibration isolating device prevents ultrasonic vibrations from thedie segment from entering the body of the forming die.
 5. The formingdie of claim 4, wherein the at least one vibration-isolating device is alow friction pad.
 6. The forming die of claim 1, further comprising adie segment adapting fixture, wherein the adapting fixture is mountedwithin the body of the forming die, wherein the die segment is mountedwithin the adapting fixture, and wherein the at least one vibrationisolating device is mounted between the die segment and the adaptingfixture.
 7. The forming die of claim 1, wherein the at least onegeometric feature includes a cylindrical bore, and wherein thecylindrical bore is oriented transversely, side-to-side, within the diesegment.
 8. The forming die of claim 1, wherein the at least onegeometric feature includes a cylindrical bore, wherein the cylindricalbore is oriented vertically within the die segment.
 9. The forming dieof claim 1, wherein the at least one geometric feature includes a squarecutout, and wherein the square cutout is oriented vertically within thedie segment.
 10. The forming die of claim 1, wherein the at least onegeometric feature includes a rectangular cutout, and wherein therectangular cutout is oriented transversely, side-to-side, within thedie segment at a predetermined angle.
 11. The forming die of claim 1,wherein the at least one die segment has a length, a height, and awidth, and wherein the at least one geometric feature formed within thedie segment permits the width of the die segment to be increased from anacoustic quarter-wavelength to a predetermined multiple thereof.
 12. Aforming die, comprising: (a) a body, wherein the body of the forming diecomprises: a cavity circumscribed by the body and at least one openingin the body; (b) at least one die segment, wherein the at least one diesegment is adapted to be inserted into the at least one opening in thebody of the forming die and be adjacent to the cavity, and wherein theat least one die segment is further adapted to receive ultrasonicvibrations; (c) at least one source of ultrasonic vibrations incommunication with the at least one die segment for directing ultrasonicvibrations into the at least one die segment, wherein the at least onesource of ultrasonic vibrations is either embedded within the at leastone die segment or external to the at least one die segment; and (d)optionally, at least one geometric feature formed within the at leastone die segment, wherein the at least one geometric feature affects theultrasonic vibrations in a predetermined manner.
 13. The forming die ofclaim 12, further comprising at least one vibration-isolating devicepositioned between the die segment and the body of the forming die,wherein the at least one vibration isolating device prevents ultrasonicvibrations from the die segment from entering the body of the formingdie, and wherein the at least one vibration-isolating device is a lowfriction pad.
 14. The forming die of claim 12, further comprising a diesegment adapting fixture, wherein the adapting fixture is mounted withinthe body of the forming die, wherein the die segment is mounted withinthe adapting fixture, and wherein the at least one vibration isolatingdevice is mounted between the die segment and the adapting fixture. 15.The forming die of claim 12, wherein the at least one geometric featureincludes a cylindrical bore, and wherein the cylindrical bore isoriented either transversely, side-to-side, within the die segment orvertically within the die segment.
 16. The forming die of claim 12,wherein the at least one geometric feature includes a square cutout, andwherein the square cutout is oriented vertically within the die segment.17. The forming die of claim 12, wherein the at least one geometricfeature includes a rectangular cutout, and wherein the rectangularcutout is oriented transversely, side-to-side, within the die segment ata predetermined angle.
 18. The forming die of claim 12, wherein the atleast one die segment has a length, a height, and a width, and whereinthe at least one geometric feature formed within the die segment permitsthe width of the die segment to be increased from an acousticquarter-wavelength to a predetermined multiple thereof.
 19. A formingdie for use in automotive applications, comprising: (a) a body, whereinthe body of the forming die comprises: a cavity circumscribed by thebody and at least one opening in the body; (b) at least one die segment,wherein the at least one die segment is adapted to be inserted into theat least one opening in the body of the forming die and be adjacent tothe cavity, and wherein the at least one die segment is further adaptedto receive ultrasonic vibrations; and (c) optionally, at least onegeometric feature formed within the at least one die segment, (i)wherein the at least one geometric feature affects the ultrasonicvibrations in a predetermined manner, and (ii) wherein the at least onegeometric feature includes a cylindrical bore that is orientedtransversely, side-to-side, within the at least one die segment; acylindrical bore that is oriented vertically within the at least one diesegment; a square cutout that is oriented vertically within the at leastone die segment; a rectangular cutout that is oriented transversely,side-to-side, within the at least one die segment at a predeterminedangle; or combinations thereof.
 20. The forming die of claim 19, whereinthe at least one die segment has a length, a height, and a width, andwherein the at least one geometric feature formed within the die segmentpermits the width of the die segment to be increased from an acousticquarter-wavelength to a predetermined multiple thereof.